DE1683037A1 - Panels and processes for their manufacture - Google Patents

Description

PATENT LAWYERS

PATENTANWÄLTE LICHT, HANSMANN, HERRMANN 8 MÖNCHEN 2 ■ THERESl ENSTRASSE 33

Dipl.-Ing. MARTIN LICHT Dr. REINHOLD SCHMIDT Dipl.-Wirtsch.-Ing ^ AXEL HANSMANN Dipl.-Phys. SEBASTIAN HERRMANN

Munich, December 22, 1967

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HOME COMFORT PRODUCTS CO. Princeville, Illinois
POBox 68
V.St.A.

Wainscoting and its method of manufacture.

The present invention relates generally to lightweight, rigid paneling having a foam core low density, and more specifically, a panel made with a core foamed in place will.

In the past, wainscoting was made with thin outer skins and cores made of plastic foam low density, in which the outer skins with a

109835/0395

Patent Attorney Dl ·: · '"ng. Martin Licht, Dipl.-Wirfsch.-Ing.Axel Hantmann, Dipl.-Phys. Sebastian Herrmann

• MDNC.i.'S 2, FHERESIENSTRASSE 33 · Telephone: 281202 · Telegram address: Lipatli / Munich

Oppenauer office: PATENT ADVOCATE DR. REINHOLD SCHMIDT

preformed core were connected. Foamed-in-place cores were found unsatisfactory because entrapped gas pockets and / or irregular expansion of the core created unsightly bumps and depressions in the thin outer skins as it was formed. It was not sufficient to simply provide vent holes because an uneven core expansion often included a gas pocket, for example due to the clogging of a vent hole. A limited solution to this problem has been proposed in German patent application H 61 848 V / 37d of February 14, 1967. In this proposal, the skins were stretched by preheating, so that they closely and contract smoothly during cooling after the formation of the _core%. Although satisfactory paneling can be produced by this process, a significant percentage of reject panels is produced since the tight outer skins are in any case incapable of compensating for extremely large depressions and bulges.

Therefore, there is that underlying the present invention Task to overcome the above and other difficulties that exist in the prior art, in creating new and improved wainscoting with a foamed-in-place core, the present invention the lining of inner pieces of the

BATH ORIGINAL 109835/0395

Frame with a strip of gas-permeable fabric in communication with one or more ventilation holes. The strip forms a drainage channel for the vent holes and also prevents the clogging of a vent hole by allowing the core fabric to pass through the vent hole is pressed. The strip is also pliable and can be compressed to uneven, excessive and compressed to compensate for insufficient core expansion «Preferably, the not yet expanded raw foam is laid in a row attached to a lower piece of the wainscot, which is sandwiched between mold plates that are canted about 10 are. In this way, the expansion of the core takes place mainly upwards, with the excess gas in front of the in the core located is pushed towards the expansion. Further connect Part of the strip and core form a high-density layer that reinforces the wainscoting The core connects to the paneling. It is therefore an object of the present invention to provide an equal f moderate expansion of a foamed-in-place wainscot core by preventing trapped gas pockets support financially.

Furthermore, according to the invention, unsightly bulges are intended and depressions in the outer skin of paneling are avoided,

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It is also intended to provide a method for the satisfactory and economical production of paneling which have foamed cores in place.

It is also a durable, light and stiff paneling to be created, which is thereby produced economically it can be that a minimum of conventional and generally available materials are used for their manufacture that is suitable for normal mass production processes are.

Furthermore, according to the invention, a structure and a method for the production of paneling and the like are to be created that provide a frame that gives them strength and rigidity, flexible and resistant under the influence of heat Plastic outer skins, which can be embossed with a decorative embossing, and which have a low-density core that is fits closely to the inner shapes of the outer skins.

Furthermore, according to the invention, a layer with a high density is intended created along the core reinforcing the paneling and securing the core into the paneling.

Other objects and advantages of the present invention will become apparent from the following detailed description and drawings

10983 5/0395

Claims with reference to the accompanying drawings.

For the purpose of illustrating the invention, there is shown in the drawings an embodiment which is presently in use is preferred. It should be understood, however, that the present invention is not limited to the precise arrangements shown and training is limited. In the drawings are: Jj

Fig. 1 is a front elevational view of paneling incorporating a represents preferred embodiment of the invention

and is made in accordance with a preferred method, FIG. 2 is an enlarged partial sectional view taken along FIG

Line 2-2 in the direction of the arrows in FIG. 1, FIG. 3 shows an enlarged partial sectional view of a corner of FIG

Paneling shown in Fig. 1, Fig. 4 is a schematic partial plan view of paneling in which the application of the raw foam, the sighting of the expansion of the core and the escape of the excess

Gas d s are illustrated,
Figure 5 is a schematic end sectional view of the paneling and a typical forming apparatus used in the manufacture

6 is a schematic end sectional view of the paneling and FIG of the molding device during expansion and hardening of the core.

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Referring now to the drawings in detail, wherein like reference characters are used for like parts In FIG. 1, paneling according to the present invention is shown, generally designated by the reference numeral 10 is designated. ¥ ie shown, depending on the intended use of the paneling and the desired decoration, one or both sides of the paneling can be provided with an embossed surface pattern 13 and 15 in order to, for example, in FIG 1 to form typical ornate wainscoting surfaces 14 and 16. It should of course be pointed out that there are innumerable Variations in the manner and details of the coughs can be made that are used for such decorations «,

An outer frame shape 20 of the paneling, which is shown in Fig. 1 in dashed lines, is formed by longitudinal frame pieces 21,23 and cross pieces 22,24 of a U-shaped Partly formed. As shown, the U-pieces 21 have miters up to their ends and form the rectangular one External shape of the paneling 10. Of course, many shapes other than rectangular, e.g. oval, square, hexagonal, etc. can also be used. can be made, and therefore the paneling according to the invention can have any external shape. The U-pieces have inwardly extending edge surfaces 25,27 and a web connecting them 26, which is the peripheral edge of the paneling 10

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speaks, as can be seen in FIGS. 2, 3 and 4. the U-pieces 21-24 can be made of any suitable rigid material such as plastic or steel; it was however, it has been found that a lightweight aluminum is very suitable as a manufacturing material for these parts. The enlarged partial view a corner of the paneling according to Fig. 3 shows that the mitered ends of adjacent U-pieces to a small extent May be spaced apart to form a vent hole 28 at each corner of the paneling 10.

A strip of gas-permeable material 30 covers the entire inner length of the longitudinal pieces 21, 23 and bridges this Ventilation hole 28 at the corners to partially cover a short piece of the cross members 22,24 as best is shown in Figs. The strip 30 is a relatively flexible and compressible plastic foam with open cells with a dimension with which it fits exactly into the U-pieces between the inwardly directed side surfaces 25,27 fits and rests on the connecting web 26. Preferably the material from which the strip 30 is made should be a foam with relatively even and fine cells, E.g. an elastic polyurethane foam, which is a reaction product of organic substances with two or more active hydrogen groups such as derived from hydroxyl, amine, amide, etc., and an organic polyisocyanate. Further

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v / ground auxiliaries such as silicone, catalyst, water and neutral blowing agents are used to promote the chemical reaction, control the cell structure of the foam and expand the mass during the reaction. Since the strip bridges the corners of the paneling at the mitered ends of adjacent U-parts, it is in communication with each vent hole 28. Two durable and relatively thin outer skins 40 _t 42 with a suitable adhesive 45 to the opposite outer sides of the frame 20 the corresponding inwardly extending edge surfaces 25, 27 are glued on. As shown in the drawings, the outer skins 40, 42 are cut to match the external shape of the paneling and are spaced apart by the webs 26 to form the outer surfaces of the paneling 10. Any suitable material, such as, for example, sheet metal, can be used for the outer skins 40, 42; however, a thermoformable plastic sheet is preferred because of the ease with which an embossed surface pattern can be formed therein. For example, acrylonitrile butadiene styrene has been found to be an excellent material for this purpose.

A low density core 50 made of a relatively stiff plastic foam completely fills the interior of the paneling 10 the end. The core 50 can be formed from a commercially available foam, for example a relative

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moderate, stiff, cellular urethane. The core 50 is foamed in place, that is, it is foamed to fill the entire interior space of the paneling 10. During the formation of the core 50, a portion of the raw foam and strip 30 of gas permeable fabric combine to form a hardened layer 55 of high density. Depending on the type of plastic foam chosen for the strip 30 and core 50, the layer 55 can be a chemical combination. When the core 50 becomes hard, it places itself as a layer on the inside of the outer skins 40, 42 and on the inside of the edge surfaces 25, 27 and the webs 26 of the U-Tiles 22, 24. ^T he hardened layer 55 amplifies the paneling 10 and connects the core 50 fixed to the longitudinal members 21,23. It is therefore not absolutely necessary to use an adhesive 45 between the frame 20 and the outer skins 40, 42, since the formation of the hardened core is sufficient in most cases to produce a solid, uniform, layered panel structure, although the use of the Adhesive 45 is preferred.

The strip 30 of gas-permeable fabric, which is a Plastic show »with open eggs takes part of the adjacent raw and expanding foam of the core evenly on · The evenness of animal absorption through the relatively uniform and fine pelts of the stripe 30 is such that the high density layer 55 after

ORIGINAL BATHROOM 109835/0395 -

Hardening is very precisely limited and has almost completely even and straight edges. Furthermore, the stripe is the same 30 due to its flexibility and compressibility from uneven, excessive and lack of tern expansion. The remaining part of the strip 30, which is between the web 26 and the layer 55 is slightly compressed, always remains open to form a channel through which the excess Gas to the vent holes 28 can escape. The strip 30 prevents the vent holes from being clogged 28, which could be caused by forcing core foam through the vent holes. In addition to the puncture of the reinforcement and the tight connection of the core 50, it was found that the layer 55 was excellent Forms a hold for fastening means which run through the web 26. That is, if it is desired, for example If hinges or similar fittings are to be attached to the edge of the paneling, such fittings can be Iron screws are fastened, which run through the web 26 and anchored in. E'er layer 55 with high density will.

The preferred method for producing the paneling according to the invention is described in connection with the secematic views of FIGS. 4, 5 and 6. ^r because it is desirable

BAD ORIGINAL 10983S / G395

To apply the process steps of preheating and expansion of the outer skins 40, 42, reference can be made to the above further proposal with regard to the special features of these process steps and the structural details of the device used for this purpose A correspondingly designed mold plate is required, for example the base mold plate 6C ₁ which is shown in FIGS. 5 and 6. The bottom mold plate 60 is mounted in a typical mold device 63, which is formed by a base plate 65 and alignment blocks 67. The alignment blocks 67 are spaced from one another at important locations along the base plate 65 to receive the bottom mold plate 60, as shown in the drawing. Pins 68 protruding from the inside of the alignment blocks 67 serve to abut the web 26 of each U-part at points that are spaced apart from one another and thereby to precisely arrange and align the frame 20. It should be noted that the former 63 is inclined in the transverse direction at an angle of about 10 °. It should also be pointed out that the base plate 65 of the molding device can run on rollers 70 so that the entire molding device 63 and the paneling contained therein can easily be displaced in the longitudinal direction. A nozzle 75 for the introduction of raw, unfoamed foam is arranged directly above the bottom mold plate 60.

109835/0395 BAD

As is known in the art, the reaction parts that make up the foam come from separate sources 77,78 The nozzle 75: is arranged in such a way that it supplies the raw, unfoamed Foam in places below the longitudinal center line Applies paneling. However, if the paneling has a part with a deep pattern, the raw foam should be in that part with a deep pattern along a longitudinal row of this pattern. brings v / earth. In some cases, depending on the pattern, especially with deeper patterns, it may be necessary to use the raw foam in the deeper parts of the pattern both above and below the longitudinal center line of the paneling.

The preferred process for the production of the paneling is only described very generally in the present description, as improved and refined designs of the mold, molding device and nozzle are possible, depending on the particular one '. Paneling and its intended use, first of all the outer skins 40, 42 are produced, whereby they can be provided with an embossed surface pattern 13, 15 and / or can be expanded by preheating. In the one shown For example, an embossed outer skin 42 is arranged on the bottom mold plate 60, which is designed so that it is exactly the desired The final shape of the outer skin 42 corresponds. Preferably, an adhesive is applied to the outer surfaces of the inwardly

109835/0395 BADORfßfNAL

Aligned side surfaces 25,27 of the U-parts 21 to 24 are applied, and the frame 20 is assembled on the outer skin 42 in the molding device. The web portions 26 of each .U-member lie on the pins 68 on in order to ensure accurate alignment of the U-parts in the assembly of the frame, ^T he longitudinal pieces 21,23 are then along its entire length with a strip of gas permeable material 30, which completely fills the space between the side surfaces 25, 27 and rests against the inner surface of the webs 26. As shown most clearly in FIGS. 3 and 4, the strip 30 bridges the mitered frame corners via the vent holes 28 in order to also cover a short piece of the mitered ends of the U-parts 22,24. Then a certain amount of unfoamed raw foam 50 'is applied in a row in the longitudinal direction of the paneling in a single operation. That is, the raw foam 50 'is passed through the nozzle 75 when the. Forming device 63 with the paneling therein moved past it, applied in a uniform row along the lower portion of the paneling to form the pattern shown in FIG. Preferably, the raw foam 50 'is applied in the deeper parts of the pattern and in a row below the longitudinal centerline of the paneling, then an outer skin 40 is applied to the opposite side surfaces 25 of the frame 20 and a heavy upper mold plate 80 is placed over it »A handle 85 or like that can

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be provided so that the upper mold plate 80 can be easily put on and removed. The paneling 10 is between Form plates 60,80 and the tenons 68 included, whereby the frame 20 and the skins 40,42 during the formation and Hardening of the core 50 held in the desired positions It should be noted that the plastic foam core can be of the type which generates some heat due to and during the curing reaction itself, and that this plastic foam core could expand and harden by itself at normal room temperature. Of course, by exercising v / rne accelerates the curing reaction on the entire arrangement for a certain time. The arrangement is thus heated and the raw core 50 is expanded and hardened to fill the interior of the panel 10. The expansion takes place mainly in the upward direction of the transverse slope of 10 ° instead, reducing the excess gas in front of the expanding foam through the uppermost strip 30 and the vent holes 28 is printed across. When the raw core 50 * touches the Strip 30 is the raw core foam 50 'slowly and evenly absorbed by the strip 30. If the expansion is uneven, is too strong or too weak, the strip 30 compensates for this by giving slightly. When hardening will a high density layer 55 is formed along the strip 30 to reinforce the paneling and to hold the core 50 in place to be connected to the frame 20, after complete removal

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Stretching and hardening of the core 30, the core is fixed along a layer to the inside of the outer skins 40, 42
and connected to the frame 20, thereby creating a strong, uniform panel structure.

The present invention can be embodied in other particular forms without departing from the scope of the Invention, and therefore the scope of the present invention, should be understood only by the appended claims and not outlined by the foregoing description.

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Claims (18)

Patent application: paneling and process for its manufacture. Pat ent claims j 1. / paneling structure, characterized by the combination following features: an outer frame shape (20) with one passing through it Vent hole, a strip (30) of gas permeable fabric in communication with the vent hole (28) and lining a portion of the frame, two durable and relatively thin outer skins (40,42) having their edges on opposite sides Adhere surfaces of the frame (20) and the spaced apart outer surfaces of the paneling form, and a core (50) of relatively low density rigid foam that is foamed in place, 109835/0395 Patent attorneys Dipl.-Ing. Martin Licht, Dipl.-Wirtsch.-Ing. Axel Hansmann, Dipl.-Phys. Sebastian Herrmann 8 MDNCHEN 2, THERESIENSTRASSE 33 · Telephone: 281202 · Telegram address: Upofli / Munich Bank details: Deutsche Bank AG, Munich branch, Dep.-Katso Viktualienmarkt, account no. 70/30638 Bayer. Vereinsbank Munich, branch. Oskar-von-Miller-Ring, account no. 882495 · PoslscJieck account: Munich No. 1i33 V BATH ORIGINAL _ I to fill in the interior of the paneling, in layers is firmly connected to the outer skins (40, 42) and the frame (20) and to a part of the gas-permeable material of the strip (30) is united in a relatively hard layer (55) of high density which reinforces the frame and the core (50) is fixedly connected to the frame, the remainder of the gas-permeable material being a connecting channel through the strip (30) between the layer (55) ^ f and the frame (20) forms, 2. paneling structure according to claim 1, characterized in that that the gas permeable fabric of the strip (30) is a relatively compliant foam with open cells, and that said remaining part of the strip (30) between the layer (55) and the frame (20) during the formation of the Core (50) is slightly compressed on the spot, 3. paneling structure according to claim 1, characterized in that that one of the outer skins (42) is a plastic film which can be molded under heat and on which an embossed surface pattern is formed, 4. paneling structure according to claim 3, characterized in that that the one outer skin (42) consists of acrylonitrile butadiene styrene and that the gas-permeable substance of the strip (30) made of relatively resilient and compressible plastic foam and the core (50) made of relatively stiff 109835/0395 consist of corrugated urethane, A paneling structure according to claim 4 characterized in that the high density layer (55) along the strip (30) is a chemical union of the core and the strip created during the formation of the core in place ; 6. paneling structure according to claim 1, characterized in that the frame is formed from parts (21,22,23,24) with a U-shaped cross-section, the inwardly extending edge surfaces (25,27) and a web connecting the edge surfaces ( 26), which forms the circumferential edge of the frame shape, and that the strip (30) is arranged in the frame between the side surfaces (25 _f 27) in contact with the web (26). 7. paneling structure according to claim 6, characterized in that the circumferential shape is rectangular and that the Frame consists of U-parts made of metal and the ventilation hole (28) at a corner of the peripheral frame through a gap is formed between the U-parts « 8. paneling structure according to claim'7 , characterized in that the strip (30) of gas-permeable material bridges the corner along two U-parts (22,23) to the ventilation hole 109835/0395 (28) to be completely separated from the core (50) and thereby to prevent the fabric of which the core (50) is made from passing through the vent hole during the formation of the core is pressed, 9, paneling structure according to claim 8, characterized in that that the frame is composed of four U-parts, which are mitered at their ends to form the corners of the frame circumference, and that the vent hole (28) through a Space between the adjacent ends of the U-parts is formed on their webs (26), 10, paneling structure according to claim 9, characterized in that the frame consists of two longitudinal parts (21, 23) and two transverse parts (22,24) is formed, a vent hole (28) being provided at each corner of the frame, and that two strips (30) are provided, each of which completely line one of the longitudinal pieces (21 or 23) and around all of them Run around corners in order to only partially line the transverse parts (22 or 24), 11, paneling structure according to claim 10, characterized in that that the gas-permeable material is a relatively thin, resilient foam, said remaining part is somewhat compressed between the layer (55) and the web (26) in the formation of the ■ Ko.ras, one of the outer skins 10983S / 0395 thermoformable plastic material with an embossed surface pattern and the core (50) is a foamed and thermoset plastic foam is, 12. A process for the production of paneling with ^% foamed-in-place cores, characterized in that a rigid outer frame shape is assembled with _a ventilation duct running through it, the edges of a durable and relatively thin outer skin are glued to one side of the frame, the inner surface of a frame piece is lined at one point with a strip of gas-permeable material ,. on which the strip of gas-permeable material is in connection with the vent hole, a certain amount of uncured raw foam is applied to the inside of the outer skin in the frame, the edges of a second hairable and relatively thin outer skin is glued to the opposite side of the frame, around the strip and enclose the raw foam inside the paneling structure thus formed, and expand and harden the raw foam to fill the interior with a low density core of relatively rigid foam that adheres in layers to the frame and outer skins, which upon expansion excess gas formed can escape through the gas-permeable strip along the frame and out of the vent hole during the curing of the filling, 109835/0395 to avoid the formation of air pockets or holes in the hardened Avoid core 13 · Method according to claim 12, characterized in that the wainscoting is enclosed between mold plates, around the frame and the outer skins during the formation of the core into the desired To keep orders 14. The method according to claim 13, characterized in that the mold plates are slightly inclined so that the
Vent hole is at a higher point, 15, the method according to claim 14, characterized in that the paneling is rectangular and at each corner of the
Rectangle a ventilation hole is provided, and that the
gormplatten hold the longitudinal frame parts of the paneling horizontally and the transverse frame parts inclined so that there are two ventilation holes at higher points, Process according to claim 15, characterized in that one of the outer skins is first shaped in order to form an embossed surface pattern on it, the corresponding mold plate being designed accordingly, that both outer skins are then preheated in order to cause the outer skins to expand slightly, and the core by heating the in the
Molded composite paneling hardens, 10983 5/0395 17. The method according to claim 16, characterized in that that the attachment of the uncured raw foam is made that one in a single operation Row of raw foam along the length of the paneling below the longitudinal center line attaches so that the raw foam is upwards in the direction of the at higher points located vent holes expands. 18. The method according to claim 17, characterized in that that the cross frame parts of the paneling by about 10 ° compared to the Are inclined horizontally and the raw foam in a row in the deepest parts of the embossed surface pattern is attached " 109835/0395 . ^ ³ Empty soap